Stainless steel LED power switch

ABSTRACT

An encapsulated LED switch that incorporates a MOSFET power drivers, high current transistors, or other suitable power drivers in a PCB that attaches to the LED switch such that a low power LED switch controls the output of a high-power driver. The selected power driver PCB can be adapted to different load requirements by making simple changes. The PCB&#39;s can be interchanged to provide for a predetermined output power required for a particular application. In addition, the wire gauge size of the wires attached to the MOSFET power driver PCB can also be varied to match intended load requirements. For applications in which the LED switch is used in hostile environments, such as marine applications, the LED switch and its associated power driver PCB are encapsulated to protect the circuitry from environmental factors such as high humidity, salt water, etc.

CLAIM OF PRIORITY

This application is a divisional of U.S. patent application Ser. No.15/013,999 filed Feb. 2, 2016, which claims the benefit of theprovisional patent application entitled “LED/MOSFET Two-Stage PowerSwitch”, filed Feb. 2, 2015, bearing U.S. Ser. No. 62/111,083; theentire disclosures of the foregoing are incorporated in their entiretiesby reference herein.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to LED switches in general, and LEDswitches for use in marine environments in particular. Further, itrelates to compact LED switches that use integral power drivers tocontrol high-current applications such as pumps and horns with a smallswitch assembly. The integral power drivers can be MOSFET power drivers,high current transistors or other suitable power drivers.

Description of the Related Art

Presently 19 mm LED Stainless Steel Switches are used for a variety ofapplication. In particular, they are frequently used in marineapplications due to the advantages of small size and durability theyprovide. Stainless steel LED switches in particular provide advantagesin the hostile environment found in marine applications. Although verypopular, prior art LED switches are limited in the number ofapplications they can control due to the limited amount of current theycan output. Typically, an LED switch by itself is limited to low DC amploads. In particular, prior art LED switches provide up to 5 DC Amploads (resistive) or 3-amp loads (Inductive), and as a result, they areunsuitable for high current applications such as pumps and horns.

While stainless steel is an excellent choice of material for fabricatingthe encapsulation sleeve due to its strength, durability and resistanceto environmental factors, those skilled in the art will recognize thatany other suitable material can be used so long as it performs well inthe environment that the sleeve is used in.

In marine environments, boats and marine vehicles of all sizes place apremium on space due to the space limitations on any size boat or ship.One an advantage provided by LED switches is that their small size isuseful on boats of all sizes due to the size and storage constraintsthat all marine vehicles have. A problem associated with prior art LEDswitches is that they are not capable of carrying heavy currents, and asa result, there are a variety of applications and devices that theycannot be used for because they cannot deliver the current necessary tooperate those devices. It would be desirable to have a small compactdevice such as an LED switch that was capable of supplying high currentmodes.

While these various prior art LED switches accomplish their intendedpurposes, they are not suitable for controlling high-currentapplications. As a result, the prior art has failed to provide a compactswitching assembly that takes minimum space and is resistant to hostileenvironments, while simultaneously producing high power outputs.

SUMMARY OF THE INVENTION

The present invention provides an encapsulated LED switch thatincorporates a new MOSFET power driver, or high power transistor PCB(printed circuit board) that attaches to the LED switch such that a lowpower LED switch controls the output of a high power driver. The PCB isattached to the LED switch and the resulting switch assembly is insertedinto a mold and sealed via epoxy or a suitable alternatives to provide athermally conductive, waterproof and ignition proof switch. The selectedMOSFET or high power transistor driver PCB can be adapted to differentload requirements by making simple changes. The PCB's can beinterchanged to provide for a predetermined output power required for aparticular application. In addition, the wire gauge size of the wiresattached to the power driver PCB can also be varied to match intendedload requirements. For applications in which the LED/MOSFET switch isused in hostile environments, such as marine applications, the LEDswitch and its associated MOSFET power driver PCB are encapsulated toprotect the circuitry from environmental factors such as high humidity,salt water, etc.

These and other objects, features and advantages of the presentinvention will become clearer when the drawings as well as the detaileddescription are taken into consideration.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention,reference should be had to the following detailed description taken inconnection with the accompanying drawings in which:

FIG. 1 illustrates a typical LED 5 A VDC Amp switch.

FIG. 2 illustrates a MOSFET power driver PCB.

FIG. 3 illustrates a preferred embodiment of the power switch assemblycomprising an LED switch and a MOSFET power driver PCB.

FIG. 4 illustrates a preferred embodiment of the power switch assemblycomprising an LED switch and a MOSFET power driver PCB with a sealedencapsulation sleeve.

FIG. 5 illustrates a preferred embodiment of the power switch assemblycomprising an LED switch capable of providing high current loads.

FIG. 6 illustrates an alternative preferred embodiment of the powerswitch assembly that provides a programmable two-circuit navigation andanchor light driver circuit.

FIGS. 7-8 illustrate alternative preferred embodiments of the powerswitch assembly that provide programmable circuits capable of drivingmultiple solenoid driver circuits.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The invention provides a sealed high-power switch that is encapsulatedto protect the switch from environmental factors. For ease ofdiscussion, the invention will be discussed in terms of use with marineequipment. However, those skilled in the art will recognize that theinvention provides the same benefits to a wide range of otherapplications in many fields, such as aviation, automotive, computers,etc.

In FIG. 1, a prior art LED switch 1 is shown. This particular switch isfabricated with a stainless-steel sleeve to protect the switch fromcorrosive elements that are typically found in marine environments. Oncethe LED switch 1 is fabricated, the stainless-steel sleeve is sealedwith an environmentally insensitive material to prevent exposure of theelectrical and mechanical components to the external environment. In thepreferred environment, the stainless-steel sleeve is filled with epoxy,but any other material can be used that is suitable for the task.Likewise, the sleeve can be fabricated with material other thanstainless steel so long as the material is suitable for its intendedtask.

FIG. 2 illustrates a power driver PCB 2. In the preferred embodiment,the power driver PCB 2 is sized to have approximately the same width asthe LED switch 1 such that they can be packaged together more easily.

FIG. 3 illustrates a preferred embodiment of the power switch assembly 3comprising an LED switch 1 and a MOSFET or high-power transistor powerdriver PCB 2. As shown, the led switch 1 and the MOSFET or high-powertransistor power driver PCB 2 are sized with roughly the same width forpackaging purposes. In addition, power lines 3-4 are shown attached tothe output of the MOSFET power driver PCB 2. Power lines 3-4 providepower to current intensive devices on marine or other equipment such aspumps, horns, etc. Ground line 4 is also illustrated.

FIG. 4 illustrates a preferred embodiment of an encapsulated powerswitch assembly 5 comprising an LED switch 1 and a MOSFET or high-powertransistor power driver PCB 2 that is enclosed in a sealed encapsulationsleeve 6. In the preferred embodiment, the encapsulated power switchassembly 5 is sealed with epoxy to isolate the internal circuitry fromthe environment.

The following FIGS. 5-8 are examples of circuits that can take advantageof the invention. However, those skilled in the art will recognize thatany number of circuits can be designed to perform a wide variety offunctions.

FIG. 5 illustrates a preferred embodiment of the power switch assemblycomprising an LED switch capable of providing high current loads. Anadvantage of the invention is that the functional characteristics of theswitch can be easily altered based upon the PCB selected for aparticular function. By way of example, the circuit shown in this figureis capable of providing current loads up to 20 ADC to a device. Thisembodiment uses a BT15LEDSW-M circuit that provides a Momentary 15 ADC.Another alternative embodiment uses a commercially available BT15LEDSWcircuit, which is an On/Off 15 ADC. A further alternative embodiment isthe BT15LEDSW-MF is also a Momentary 15 ADC, but differs in that it hasa resettable thermal breaker. Yet another alternative preferredembodiment uses a BT15LEDSW-F, which is and On/Off 15 ADC with aresettable thermal breaker. The PCBs provided as an example arecommercially available from Bocatech, Inc. For all of the resettablethermal switches, a single thermal breaker, such as a commerciallyavailable UL Bussman thermal breaker, among others, is installed in-linewith the power input to the switch. Of course, any number of othersuitable switches can be used to suit a particular purpose. As a result,the foregoing embodiments are exemplary only and do not limit the typesof PCBs that can be used as a component of the switch. In practice, theinvention envisions switches having a variety of ratings including butnot limited to 5, 10, 15 and 20 ADC.

Those skilled in the art will recognize that any color led can beselected based on design preferences.

FIG. 6 illustrates a preferred embodiment of the power switch assemblythat provides a programmable two-circuit navigation and anchor lightdriver circuit. The PCB circuit used in this embodiment is a BTNAVLEDSWcircuit that is commercially available from Bocatech, Inc. The circuituses a bi-color LED switch that functions as follows:

1. One push of the switch button activates the blue switch LED andactivates both circuit outputs to illuminate the navigation and anchorlights on a vessel.

2. The second push of the switch button turns off the blue switch LEDand turns on the red switch LED and activates only the circuitcontrolling the anchor lights.

An alternative embodiment uses a microcontroller on the PCB to provide atimer function that automatically turns off the navigation lights in theevent the boat owner forgets to do so.

FIGS. 7-8 illustrate other alternative preferred embodiments of thepower switch assembly that provide programmable circuits capable ofdriving multiple solenoid driver circuits. In addition, the PCB can befabricated from two separate PCBs that are plugged together andassembled as a single switch assembly. This allows PCBs having variousfunctions be joined together for a particular application. As a result,the resulting circuit can provide multiple functions such as solenoiddrivers, water pressure sensors, current monitoring, etc. In addition,safety features such as alarms can be incorporated into the PCB thatalerts the boater by flashing the red LED on a bi-color switch.Likewise, those skills in the art recognize that audible alarm can alsobe built into the switch.

As can be seen, the invention provides a low power switch that controlsa high power MOSFET driver to provide power to a variety of devices,while protecting the circuitry from harsh environments, such as inmarine applications. Further, the switch disclosed herein can bedesigned to use one of many PCBs that are capable of forming any numberof functions.

Because the switches disclosed herein may be designed withmicroprocessors for micro controllers, they would in effect become smartswitches that include one or more of the following capabilities:

1. Programming capabilities (e.g., On/Off, Momentary, multimode etc.).

2. Communications capability (e.g. NEMA2000, CAN, RS232, USB, etc.).

3. Current monitoring, including shutdown.

4. Overvoltage and undervoltage monitoring.

5. Multicolor LED switch controls.

6. Visual and audible alarm functions.

7. Sensor applications, such as water pressure, air pressure, fuelpressure, oil pressure, vacuum pressure, etc.

8. Timer and counter functions with indicators.

9. Data acquisition.

10. Adaptable to switches of different types and sizes.

11. Ignition proof.

As can be seen from the foregoing discussion, the invention provides anumber of advantages. It is inexpensive to manufacture, it is compactand lightweight, it provides effective protection of electroniccircuitry from the outside environment, and can be use in a wide varietyof environments and technical and commercial areas.

While the invention has been described with respect to a preferredembodiment thereof, it will be understood by those skilled in the artthat various changes in detail may be made therein without departingfrom the spirit, scope, and teaching of the invention. For example, thematerial used to construct the switch may be anything suitable for itspurpose, the size and shape of the encapsulated power switch assemblycan vary, the type of circuitry can vary, etc. Accordingly, theinvention herein disclosed is to be limited only as specified in thefollowing claims.

Now that the invention has been described,

What is claimed is:
 1. A high power switch assembly, comprising: an LEDswitch having an off and on position; a thermal breaker operativelyattached to the LED switch; a PCB driver operatively attached to the LEDswitch such that when the LED switch is in the on position, the PCBdriver outputs a high amperage on its output lines; a first circuitoperatively connected to said LED switch and said first circuit havingan output; a second circuit operatively connected to said LED switch andsaid second circuit having an output; a first state comprising saidoutputs of both said first and said second circuits being active; asecond state comprising said output of said first circuit being inactiveand said output of said second circuit being active; wherein operationby a user of said LED switch transitions from said first state to saidsecond state.
 2. A switch assembly, as in claim 1, wherein: said firststate further comprises said LED switch emitting a first color of light;said second state further comprises said LED switch emitting a secondcolor of light; wherein said first color and said second color aredistinct from each other.